The modular production system (MPS): an alternate approach for control technology in design and technology

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1 Loughborough University Institutional Repository The modular production system (MPS): an alternate approach for control technology in design and technology This item was submitted to Loughborough University's Institutional Repository by the/an author. Citation: YEUNG and CHOW, The modular production system (MPS): an alternate approach for control technology in design and technology. IDATER 1998 Conference, Loughborough: Loughborough University Additional Information: This is a conference paper. Metadata Record: Publisher: c Loughborough University Please cite the published version.

2 This item was submitted to Loughborough s Institutional Repository by the author and is made available under the following Creative Commons Licence conditions. For the full text of this licence, please go to:

3 The modular production system (MPS): an alternate approach for control technology in design and technology Kai-hing Yeung and Shiu-cheung Chow The Hong Kong Institute of Education, Hong Kong SAR, People s Republic of China Abstract Traditionally, programming languages which are commonly employed in school control technology are QBASIC and CFA. They have been designed based on definable procedural types. Such languages are generally easy to learn and understand, and are well suited to the requirements of small systems. However, as the complexity of systems has increased, so the limitations of the procedural approach have become increasingly apparent. In order to solve the problem, a language which meets the IEC standard has to be employed. With the aid of a well-defined programming language, more realistic-like applications and problems can be simulated and resolved. This paper introduces an alternate approach in teaching and learning school control technology. The rationale for employing a Statement List, which is a programming language which meets the IEC standard, is firstly discussed. Secondly, the feature of Modular Production System, which is a simulation to real-life industrial production system, is introduced. Thirdly, the design of a processing station using the MPS approach is described. Finally, concluding remarks on the pros and cons of applying the approach are presented. Introduction Control technology is a compulsory module for all Design and Technology studentteachers at the Hong Kong Institute of Education. During the class, student- teachers make use of the Microelectronics For All (MFA) Computer Module to assess eight digital input and output lines. For instance, they can control buggy, pneumatic valves, stepper motor, and traffic lights. The control languages employed are QBASIC and CFA with the latter being (Unilab, 1997), a LOGOlike control language based on definable procedures. In its mouse-driven version, the CFA program only allows output lines to be switched on by point-and click. Similarly, a script of commands are built up by selecting from buttons and menus. It also offers a topdown approach to programming so that students can write and save procedures as building blocks as they tackle a control problem. The majority of school control languages are based on LOGO and BASIC, and although they are useful for developing mathematical concepts and teaching accepted programming techniques, their applications for real-time processing is limited. The very nature of these languages restricts them to sequential events which is fine for tasks such as programming a traffic light. However, tasks which involve handling more than one event at a time, such as modelling a car park control system with an identification system and the simultaneous control of a barrier, require the programmer to develop multi-tasking routines. This introduces programming complications which do not arise with an electronic systems approach. This paper explores an alternate approach which employs simulation to real-life industrial production equipment in learning control technology. The rationale for using a Statement List, which is a form of control language will be firstly discussed. Secondly, the features of Modular Production System (MPS) will be introduced. Thirdly, the development, design and implementation of 184

4 a processing station using MPS will be described. Finally, concluding remarks will be presented on the benefits and limitations of using such approach. Rationale for a control language: statement list (STL) Investigations into industrial control systems revealed interesting parallels relating to control rationale. Industry s need for costeffective and flexible control systems led to the development of Programmable Logic Controllers (PLCs). These became increasingly important during the 1980s, offering an intermediate route between dedicated electronic systems and the use of computers for the control of industrial machinery. Different parts of a control application can have different programming requirements. For example, one section might be arithmetically intensive, while another might require detailed and explicit sequencing. IEC is an international standard defined by the International Electro-technical Commission. This standard addresses diverse system requirements by defining five different languages, three graphical and two textual, for expressing different parts of an application (Lewis, 1995). The languages can be mixed and matched within a given application, using different languages for different parts of the overall program. The control languages are Ladder Diagram (LD), Statement List (STL), Sequential Function Chart (SFC), Structured Text (ST), and Function Block Diagram (FBD). Among those, LD and STL are the two most common control languages for initial learners. Although Cooper (Cooper, 1997) argued that Ladder Diagram which is based on ladder logic, is good for learning control technology in schools, LD has limitations. Firstly, it has no standard approach to implementation. There are variations in ladder symbols and language facilities between the PLC systems supplied by different manufacturers. Secondly, it has poor support for structured programming. Many traditional PLC languages offer no, or at best only limited, facilities for applying structured programming techniques. This limits the scope for the application of software engineering methods and software re-use. Thirdly, it has limited support for sequencing. Many industrial applications require that operations can be controlled in sequence. Methods supporting this facility are available in existing ladder languages, but for large programs, they tend to produce code that is hard to understand. Statement List is a textual, assembler type language, typified by a simple machine model. It incorporates functions which are similar to functions in procedural programming languages such as QBASIC, PASCAL, and C and implies that PLCs can be programmed using the modern software design methodologies. For learners who have prior knowledge on writing control programs using QBASIC or CFA, Statement List can be considered a better language for them. Modular production system (MPS) Practice-oriented training is the ideal preparation for the workplace. Training on the actual production plant is often not feasible, since the risk of a malfunctioning system would be too great and the production process would thereby be considerably disrupted. A practice-oriented training system is therefore the optimum alternative. With this, trainees and skilled workers alike can be prepared for the professional demands of the job without any pressure of time or facilities. In practice, a team consisting of industrial and electrical technicians would be able to assemble, commission, operate and maintain a production plant and localise and eliminate any faults in a system. This means that in addition to professional competence, each team member is trained in order to gain additional qualifications to enable the team to work effectively. The individual qualifications are namely, (I) team spirit; (II) willingness to cooperate; (III) initiative; and (IV) organisational skills (Festo, 1997). These abilities, plus professional competence, are known as all-round performance competence and provide the key to professional career. 185

Figure 1 A MPS Station Modular Production System (Festo, 1997) is a learning system which can be used to simulate real-life industrial production equipment of varying complexity.

5 Figure 1 A MPS Station Modular Production System (Festo, 1997) is a learning system which can be used to simulate real-life industrial production equipment of varying complexity. MPS is universal, modular, and open to further expansion. The basic level can consist of simple operations and sequences, which can then be extended step by step to build a complex system. Since it is only seldom possible to enjoy the benefit of practical training on real production equipment, MPS enables optimum preparation of learners for the demands they will face in their professional lives. For example, a processing station provides a system for gaining technical knowledge such as planning, assembly, programming, commissioning, operation, maintenance and troubleshooting on production equipment. Obviously, this can be taught to various degrees of complexity. With MPS, it is possible to teach trainees areas of mechanical systems, pneumatics, sensors, programming, fault finding and quality control. Figure 1 shows a typical MPS configuration. The target students are undergraduates in electrical/electronic engineering, manufacturing engineering, instructors, and technical teachers. The support system, basic units and modules provide the fundamental building blocks which make the entire application package. The support system which consists of an aluminium profile plate as well as PLC board and trolley forms the central location for assembly of the basic units and the basic units perform individual functions, such as the picking up of workpieces. Useful functions can be carried out by using different modules such as a rotary indexing table and a drilling module. Modules and basic units are combined mechanically and via control technology to form stations which are capable of various functions. Several stations are available for standard functions such as distribution, testing, processing and storage. The functions of stations are summarised in Table 1. By means of a combination of different stations, it is possible to achieve installations with a wide range of different functions. With these installations, it is possible to deal with more complex training contents such as planning and project design, structured PLC programming techniques, operation of installations, commissioning and maintenance of Computer Integrated Manufacturing (CIM) systems, quality management, and industrial communication. 186

3 Processing process the different workpiece types such as aluminium or red plastic workpiece and; check the result of processing after the processing cycle.

6 MPS Stations Function 1 Distribution separate out a workpiece from the magazine and; make the workpiece available for a subsequent process. 2 Testing establish the material characteristics of a workpiece; check the workpiece and; either separate out a workpiece or make it available for a subsequent station. 3 Processing process the different workpiece types such as aluminium or red plastic workpiece and; check the result of processing after the processing cycle. 4 Handling remove parts from the processing station and; sort parts according to their characteristics. 5 Sorting sort parts according to their characteristics. 6 Buffer transport and separate out workpieces. 7 Assembly assemble a cylinder and; transfer the assembled cylinder to a subsequent station. 8 Hydraulic punching separate out a workpiece from the magazine; punch a hole in the workpiece and; rotate the workpiece by 180 degrees and transfer it. 9 Functional testing test the functioning of the assembled short-stroke cylinder; either reject the cylinder or make it available to a subsequent station. Table 1 Function of MPS Stations System requirements After having studied the various technical skills to be learned from each station, the Processing Station (Festo, 1996) (Figure 2a, 2b) was selected over the others because it covers a wider range of technical knowledge which is in line with the present teaching curriculum in the Institute. For instance, the Testing Figure 2a An unassembled processing station Figure 2b An assembled processing station 187

7 Areas Technical skills 1 Mechanical systems know and use mechanical components; use profile to set up automated systems; design and plan mechanical interface in systems. 2 Pneumatics know and use pneumatic components; design and develop pneumatic circuits; optimise and adjust pneumatic circuits; install tubing and commissioning pneumatic circuits. 3 Electrical engineering wire and test electrical components; design and develop electrical circuit diagrams; know about electromechanical drives; apply electrical interfaces. 4 Sensors know and use limit switches and sensors; identify different sensors; apply sensors and limit switches in positioning. Use limit switches as safety devices. 5 PLC technology understand the structure and mode of operation of a PLC; know about different types of control languages; programming different modes and functions. Table 2 Technical skills station covers only mechanical systems, sensors, and pneumatics. The technical skills which can be learned from the Processing station are summarised in Table 2. System design, construction and testing A Design Although the Processing station apparently performs a simple drilling task, the task can to be broken into different sub-tasks. In a simulated industrial context, aspects such as safety, tolerance, technical communications, etc. need to be considered in the design. The functional description of the whole drilling process is summarised in Table 3 Based on the functional description, a pneumatic circuit diagram had to be worked out and is shown in Appendix A. The pneumatic circuit diagram shows three double Start Condition Initial Position Sequence Workpiece in Feed cylinder drilling unit Rotate rotary indexing table retainer 1 raised Extend clamping cylinder Checking cylinder retracted Lower feed cylinder drilling Clamping cylinder retracted Drilling unit of Table 3 Functional description unit Raise feed cylinder drilling unit Switch off drilling unit Retract clamping cylinder Rotate rotary indexing table Extend checking cylinder Retract checking cylinder Rotate rotary indexing table 188

Figure 3 Fixing the rotary table Figure 4 Fixing the sensors acting cylinders which are controlled by three 5/2 pilot valves separately.

B Assembly and commissioning The components such as rotary table, drilling module, sensors, etc. were gathered and assembled with reference to the system requirements (Figures 3 and 4).

The plug of the control console in the I/O terminal XMG2 on the PLC board was inserted.

The pneumatic components drew six BAR compressed air for working pressure.

8 Figure 3 Fixing the rotary table Figure 4 Fixing the sensors acting cylinders which are controlled by three 5/2 pilot valves separately. The I/O interface diagram shows the actual wire connection of the PLC controller such as start, reset, initial position, special function, communication, emergency stop, networking, etc. B Assembly and commissioning The components such as rotary table, drilling module, sensors, etc. were gathered and assembled with reference to the system requirements (Figures 3 and 4). When all components were in position, the commissioning process (cable connections) was then started. A PLC board was assigned to the station. The plug of the control console in the I/O terminal XMG2 on the PLC board was inserted. The I/O terminal XMA1 on the mechanical structure of the station with the I/ O cable XMA2 of the PLC board was then connected. The station was supplied by a 24V DC max. 5A power supply. The pneumatic components drew six BAR compressed air for working pressure. C Programming with the Festo Software Tool (FST) The stepwise refinement programming technique was applied to tackle the programming task. The programming of the complete operation was divided into five submodules, namely, (I) Rotary indexing table via a timer module, (II) Rotary indexing table via a sensor module, (III) Drill hole checking module, (IV) Drilling module, and (V) Indexing and drilling module. Finally, the program was completed by joining the above five sub-modules. D Operation and testing All five sub-modules were tested sequentially (Figure 5). Modifications were made from time to time in order to fulfil the system requirements (Figure 6). Finally the complete Figure 5 Program testing Figure 6 Modifications 189

task, it may be difficult for a novice or an individual to complete because it requires broad technical knowledge in various areas such as mechanical, pneumatics, electrical engineering, sensors and

9 task, it may be difficult for a novice or an individual to complete because it requires broad technical knowledge in various areas such as mechanical, pneumatics, electrical engineering, sensors and PLC technology. It is wise to work in groups so that teamwork, collaboration, organisational abilities, and interdependence can be applied to ease the workload. Figure 7 The Processing station operation was tested and the results encouraging. Figure 7 shows the final product. Conclusion It was really a personal challenge and joy to learn control technology with the aid of real industrial production equipment such as the Festo MPS. Typical areas from industrial automation practice such as designing, assembly, programming, commissioning, operation, maintenance, and troubleshooting on production equipment were able to be experienced through various degrees of complexity. Statement List, the control language, with unlimited use of functions and functions blocks, can be used for industry-specific requirements. It offers parallel processing and multi-tasking routines which allows learners to focus on more challenging and realistic problems in schools. It also leads the learners from a school context to an industrial context. Statement List follows the international standard IEC which offers PLC users a programming environment based around familiar PLC concepts. For the studentteachers, this provides an easy adaptation from one control language to others; a situation often occurring in the real world. Although the modular kit explored by the authors was used to perform a simple drilling The MPS approach was found to be a practical method to learn control technology when compared with the traditional school approach. It provides the opportunity to combine theory into practice, utilising a challenging, yet realistic methodology. Such approach should be encouraged more in Hong Kong Schools, which traditionally rely on outdated technology, concepts, and instructional methods. Continuing the present situation will not meet the demands for an ever-changing and technically competent workforce. References Cooper, A. (1997) PIC Electronics for design and technology. The journal of design and technology education. 2, 1, Festo Didactic (1996), Modular production system: processing station manual, Esslingen. Festo Didactic (1997), Modular production system MPS: equipment range for industrial automation, Esslingen. Lewis, R. (1995), Programming industrial control systems using IEC The institution of electrical engineers, United Kingdom. Unilab. (1997), Design & technology, International Edition, Philip Harris plc. 190

10 Appendix A The pneumatic circuit diagram 191

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